Académique Documents
Professionnel Documents
Culture Documents
KNOWLEDGE FACT
LALBHAI GROUP & ARVIND LTD.
⦿ Arvind Ltd. - A flagship company of a
diversified $550 million Lalbhai group
founded in 1908
⦿ Lalbhai Group Businesses are:
› Textiles & Clothing's (Core Business)
Production
commenced 1987 1999-00 2000-01 1999-00 1999-00
Products Yarn & fabric Yarn & fabric Garment Fabric Garment
Capacity 120 mmpa. 30 mmpa 4.8 M shirts 7200 tons pa 12.0 M pcs
Amber,
Plant location Naroda Santej Bangalore Santej Vadsar &
EmBee
BUYER
MERCHANDISING SAMPLING
DEPT Confirms date
Contract seal prepared which
Development specifies exact construction of the Order is placed
(3 – 4 weeks) product
MERCHANDISER MERCHANDISER
Review & order Fabric technical hanger along At the same time the
placement with fabric swatch sent to buyer trims order is also
for approval placed
ESTEEMED CLIENTS
SAMPLING DEPARTMENT
Receive sample
Verify material / Receive materials Request trims from
request and
requisition from marketing store
material
Internal audit
In case of
rejection from Forward sample
Receive patterns Prepares samples
marketing to marketing
Remake sample
from first step
◘ RACK SAMPLE
a random sample taken from the production line
PPC DEPARTMENT
PLANNING AND IMPROVEMENT CONTROL
Open width fabric on card board rolls Total floor area = 17.53 m x 22.86m
= 400.73m²
Tubular fabric in cutled form
Total number of racks 48 - 49
Capacity = 15 – 17 tones
Fabric
issued
Daily usage = 6 – 7tones
FABRIC
STORE Package type
Fabric
Rolls (open) = 20 – 25 kg
received Rectangular shape (tubular) = approx. 35 kg
SPREADING
AUTOMATIC SPREADING MANUAL SPREADING
(2 -3 PERSONS AT EACH TABLE) (CONTRACTUAL BASED)
SPREADING OF SRIPES
SPREADING OF SOLIDS
SOME TIMES OF SOLID
PROCESS PROCESS
Loading
Spread
of roll on Opening block
perforated
to the of roll cutting
paper
M/C
Insert
stripes to Spreading Match
locate roll Spreading of blocks stripes
change
CUTTING
STRAIGHT KNIFE
GERBER (AUTO CUTTER)
(MANUAL CUTTING)
PROCESS PROCESS
Spread Pattern
Moving lay to polythene placement Marking with
Gerber table sheet over on block chalk
the lay
pieces
pieces Run the sorted out
sorted out loaded marker according to Cutting using
according to plan in the the different straight knife
the different M/C rolls
rolls
HEAT TRANSFER AND FUSING
HEAT TRANSFER FUSING
Check specs
Moon patch Cut the rolls as per width mentioned in KNP sheet &
and
pieces quantity required for shift by using roll cutting machine
selecting
received from
appropriate
cutting
sticker
Final heat
transferring Sticker Align the fusing of fabric feed to conveyer
using removed
HASHIMA HP
Trim the fused of fabric using tied scissors in exit the
rear end
EMBROIDERY
There are 3 BARUDAN LTD. Embroidery machines
2 machines with 20 heads &
1 machine with 12 head
marking as per
Receive Receipt placement
instruction of cut given
sheet and panels instruction
pattern and trims sheet
Positive is on polyester
prepared mesh (frame) positive is
the screen is
referring photo emulsion mounted on the
dryed
spec coating is done, screen
sheet turns to screen
ironing
Sewing operations
Packing in polybag
Final inspection
Sent to audit
FINISHING, PACKING & DISPATCH
Line out Lot making audit
Special finish
tagging folding Dispatch
(if any)
Check for
Button
pressing metal storage
attaching
contamination
External audit
AUDITING
PROCESS
failed passed
AUDIT
Final
Online audit
inspection
TWO CONCEPT PRODUCTION FACILITIES
• VADSAR - Designed for producing Casual wear / Cut & Sew Tee's &
Polo's
The various
rolls that are
issued to fulfill
the fabric
required are
listed according
to their weights.
Fabric Requisition
It includes the roll no, roll width, roll weight and the no. of plies that were
spread from a particular roll for 1 cut no.
Lay Information Slip
This sheet helps us to keep a record of all the rolls were used
for all the cut programs.
A RANDOM EXAMPLE
A random lot wise cut program was selected and all the
required formats of that program were checked to see if
the total fabric that is issued was actually used or not and
whether the entries done in the formats against the
system laid down in the manual were correct or not.
A total of 31 fabric rolls were issued in the
fabric requisition sheet
A total of 31 fabric rolls were issued in the
fabric requisition sheet
While the lay information slips showed :
While the lay information slips showed :
9
While the lay information slips showed :
9
5
While the lay information slips showed :
9
5
7
While the lay information slips showed :
9
5
7
3
24
That only 24 fabric rolls were actually used
Only 24 rolls were used compared
to the 31 rolls that were actually
issued. Therefore 7 rolls were
missing…….
9
5
7
3
24 7
31
When the total fabric consumption for the garment pieces actually cut was
calculated, it matched with the total fabric actually issued.
This leads to the conclusion that the workers have
spread more than 1 fabric roll together and have
done entry of only 1 roll. Therefore the rolls do not
have any record in the lay information slip and
hence seem to be missing.
Problems by this mistake…
Due to this mistake of entering
information of only 1 roll in place of 2 or
more in the lay information sheet, there
can be problem of shade variation in the
cut parts if there is roll to roll shade
variation. Since the bundle card is made
on the basis of the lay information slip,
now 1 bundle will contain cut parts of
more than 1 roll. Hence shade variation
in the cut parts and hence more
rejections.
Problems by of this mistake…
Means,
The same roll was entered in the lay information slip for 2 different lays
which is not possible.
Overall there was due to the carelessness of the workers. There is
shade variation in the cut parts hence more rejections, which is not good
in the companies point of view.
STEPS TAKEN
✓ Provided the SOP to every worker & machine,
✓ Supervisor must Check the formats time to time and must keep the
record,